The SRMs store up to 52 pallets per hour – and retrieve up to 126 pallets

Deep-freeze Logistics as a Challenge

In a deep-freeze environment picking has to be completed within 30 minutes at a maximum temperature of -5 °C. This furthers the market trend for high stock turnover and thus fully automated logistics systems. In food logistics, the share of frozen food by now ranges between 15–20 %. Logistically speaking, however, many companies in the deep-freeze industry drag behind the market development. They can barely keep up with the increasing requirements of industry and trade. At the same time, modern system design offers a lot of potential for optimization and economization. With intelligent concepts for automated processes, companies can significantly increase storage capacities, efficiency, and throughput while decreasing fixed cost.

Mydibel as Trend-Setter in the Deep-Freeze Industry

Since storage capacities have been merged and are now focused in the new warehouse complex at the head quarters, heavily hooded fork lift operators are now a thing of the past. Out of Mouscron, the family-run company Mydibel, founded in 1988, ships approx. 1,100 frozen potato products to the food industry, retail chains, and catering companies in more than 75 countries. During the design phase of his new deep-freeze warehouse, the food manufacturer decided on an automated channel storage system with shuttle technique.

Controlled via incremental encoders and light sensor systems, the Orbiter shuttle puts the pallets in the rack channel and returns to the docking station on the SRM
Schaefer Orbiter System
The supplied pallets are transferred to the conveying system.
supplied pallets are transferred to the conveying system

The Project

The extremely flexible SOS moves on two rails and does not need an upper guide rail.

By building a fully automated compact warehouse, SSI SCHAEFER as general contractor realized one of the most modern logistics solutions in the beverage industry for the beverage manufacturer Gerolsteiner. The implemented design with channel storage, Schaefer Lift&Run-System, Orbiter shuttles, and intelligent material flow control from the warehouse management system provides Gerolsteiner with an optimal use of space, increase of availability, delivery capacity, and service quality, high through-put as well as modern work stations. Beyond that, this solution offers options for further growth of the beverage manufacturer.

In two construction phases, from mid 2011 to September 2012, SSI SCHAEFER realized for Gerolsteiner one of the most modern and efficient warehouse and material flow concepts in the beverage industry. First, a warehouse complex with 9,300 storage positions was built directly at the one-way-filling system for storage of one-way products that cover 20 % of the  Gerolsteiner truss. After start-up in November 2011, the second construction phase of the compact warehouse started which led to double the capacity.

In the new, six aisle high-bay warehouse Gerolsteiner now has available around 19,000 pallet storage location. Beyond that, the design leaves room for a possible extension of the capacities up to 60,000 storage positions. The entire design is geared to sustainability and the distribution center is modularly expendable. If necessary, a further warehouse complex can thus be smoothly connected to the existing warehouse, the conveyor system, and the IT. With its path-optimized design and efficiency advantages the compact warehouse has further a positive effect on the CO2-balance of Gerolsteiner, offers significantly more storage capacity, and simplifies the service offers of the beverage manufacturer.

Information and consulting
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The project in detail

our Scope of Supply and Services

  •  Logistics and construction
     planning as construction
     stage concept
  •  Simulation and planning of
  •  Inhouse rack system as
     channel storage
  •  Schaefer Lift&Run-System
  •  Visualization
  •  Warehouse management
  •  Pallet conveyor system
  •  Turn-key project as
     general contractor
  •  Service hotline and

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